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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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16 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Spin-stabilized orbital rocket guidance

Technologies for guidance of a spin-stabilized orbital rocket are described herein. The spin-stabilized rocket includes a guidance controller. The guidance controller computes parameters of a burn of a second-stage engine of the rocket to reach a desired nominal orbit subsequent to burnout of the first stage of the rocket. The guidance controller computes the burn parameters of the second-stage engine based upon one or more desired orbit parameters and a current position and velocity of the rocket. The computation of the burn parameters is based upon a simulated point-mass model of the motion of the rocket. The guidance controller then controls the rocket to initiate a second-stage burn having the computed burn parameters.

Gilkey, Jeffrey C.↗
DOE OSTI2025

Nuclear Thermal Rocket Emulator for a Hardware-in-the-Loop Test Bed

To support NASA’s mission to use nuclear thermal rockets for future Mars missions, an instrumentation and control test bed has been built at Oak Ridge National Laboratory. The system is designed as a hardware-in-the-loop test bed for testing control elements and autonomous control algorithms for nuclear thermal propulsion rockets. The mock reactor system consists of a modular and scalable framework, using inexpensive components and open-source software. The hardware system consists of a two-phase flow loop and a mock reactor with six control drums. A single-board computer (NVIDIA Jetson) handles reactor core emulation and hosts a message queuing telemetry transport broker that allows user-deployed control algorithms to interact with the system hardware. The reactor emulator receives sensor data from the hardware and provides the simulated performance of the reactor under steady-state, transient, and fault conditions. The emulator uses a reactivity lookup table and the point kinetics equations to solve for the reactor dynamics in real time. Emulated reactor dynamics and sensor input inform the autonomous control algorithm’s decision-making in a closed-loop manner. The current system is capable of operating at 10 Hz, but faster cycle rates are an area of ongoing research. This test bed will enable NASA and other space vendors to rigorously test their autonomous control systems for NTP rockets under transient (reactor startup and shutdown), steady-state, and fault conditions to reduce development time and risk for autonomous control systems in future missions.

autonomous control↗
DOE OSTI2024

Space Nuclear Power Autonomous Control Algorithm and Control Element Test Bed

Nuclear thermal rockets are currently NASA’s preferred option for use in a manned mission to Mars in the 2040s. The communication delay between an Earth ground station and a spacecraft heading toward Mars can be up to 20 min. Therefore, controlling the nuclear rocket engine would require either a full-time reactor operator on the mission or an autonomous control system for the reactor. The latter idea of making space nuclear reactors fully autonomous has drawn more interest from stakeholders, but such an autonomous control system must be rigorously tested and validated before it is certified for human use. The cost of a full ground test for a space nuclear reactor is tremendous, so a nonnuclear mock reactor test bed was created to test and validate control elements and control algorithms for space nuclear reactors. The test bed consists of control element hardware that inputs physical measurement data into a reactor emulator to produce the reactor’s performance under steady-state, transient, and fault conditions. The control element hardware consists of six full-sized control drums equipped with servo drives and motors and is instrumented with optical encoders, resolvers, and torque sensors for drum movement characterization. In addition to the drums, a two-phase flow loop was designed and built to mimic the valves and turbomachinery associated with the propellant flow through a nuclear thermal rocket engine; components such as pressure sensors, flow meters, thermocouples, and tachometers are instrumented throughout the loop to characterize the fluid flow, valve, and turbomachinery behavior of the system. The data from the physical hardware (e.g., drum position, propellant flow rates) are input to a nuclear reactor simulator to determine the actual nuclear reactor parameters, and the data are sent back to a control algorithm to complete the control loop. The ability to conduct numerous tests of the control systems and autonomous algorithms can help validate the instrumentation and control aspects for a space nuclear reactor for every possible fault situation.

Wilson, Brandon↗
DOE OSTI2024

Demonstrating autonomous controls on hardware test beds is a necessity for successful missions to Mars and beyond

NASA and the Department of Defense are planning for a mission to Mars in the 2030s–2040s using nuclear thermal propulsion (NTP). NTP uses a nuclear reactor to heat flowing hydrogen and create thrust. A serious concern for crewed and uncrewed missions to Mars is the loss of reactor control. The reactor startup and initial rocket impulse are initiated in cislunar or near-earth orbital regions; therefore, radio communications between ground control and the NTP engine should occur in real time. However, radio communications can take more than 20 min, depending on planet positions, to reach Mars orbiters from ground control. To address this delay, local autonomous controls are implemented onboard the NTP engine to ensure acceptable operation. However, autonomous controls have not been demonstrated or implemented in research or power reactor contexts because of safety and reliability concerns. To enable autonomous controls development, demonstration, and validation, Oak Ridge National Laboratory has created a nonnuclear hardware-in-the-loop test bed. Sensors throughout the test bed relay system status and hardware response to the user control algorithm, including measurements of temperature, flow, pressure of a loop, control drum position, and drum speed. This paper discusses the development of this facility and user accessibility.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2020

High Fidelity Simulations of a Methane-Oxygen Rotating Detonation Rocket Engine

The rotating detonation combustor (RDC) is an important realization of pressure gain combustion for practical applications. The RDC system is characterized by a highly unsteady flow field, with multiple reflected pressure waves following the strong detonations and the existence of partially-burnt gases entrained within the detonation annulus during the injector recovery process. While experimental efforts have provided macroscopic properties of an RDC with a given fuel-oxidizer mixture and geometry, limited optical access and reduced lifespan of flow-field diagnostic equipment constrain understanding of the mechanisms that lend to wave stability, controllability, and sustainability. To this end, high-fidelity numerical simulations of the Air Force Research Laboratory (AFRL) methane-oxygen rotating detonation rocket engine (RDRE) are performed to provide detailed insight into the detonation physics and anomalous behavior within the combustor. The results highlight the merit of high-fidelity numerical studies in analyzing the combustion processes and injector dynamics of a complex combustion system. The simulations capture the general wave behavior observed within the experimental studies. Three different operating conditions, with varying global equivalence ratio and system mass flow rate, are considered: (1) baseline configuration, (2) high equivalence ratio, and (3) high mass flow rate. The high mass flow rate case results in increased detonation wave strength whereas the high equivalence ratio results in increased deflagrative heat release. The high equivalence ratio case results in chaotic behavior with two pairs of counter-rotating detonation waves, whereas a single pair of co-rotating waves is observed in the baseline and high mass flow rate cases. Further, parasitic combustion of the reactant mixture ahead of the detonation wave diminishes its strength and reduces propagation speed to approximately 50-60\% of the Chapman-Jouguet (CJ) condition. In this work, a detailed analysis of the detonation wave behavior, injector dynamics, and the statistics of combustion parameters are presented.

Prakash, Supraj↗
DOE OSTI2022

Balancing Impedance and Controllability in Response Reconstruction

One concept in smart dynamic testing is to match the impedance that a component experiences between test and the environment of interest, but this begs the question: how much of an impedance match is needed and could there be too much? In a prior work, the authors performed MIMO testing with a small component connected to various assemblies, each of which had a differing degree of similarity to the actual flight boundary conditions. The results showed that the fidelity of the response at locations away from the control accelerometers was highly sensitive to the impedance. This work presents further case studies to explore these ideas. Subsequent tests are presented for an assembly that presumably matched the impedance even better, and which was also much more flexible, and the results obtained are even worse than when no attention was given to the impedance. Hence, the work presented here suggests that one should seek a balance between 1.) matching the impedance and 2.) improving the controllability of the component of interest. The concepts are explored using both test data of a benchmark component, for which the environment of interest was recorded as the component flew on a sounding rocket.

Shaker Test, Operational Vibration Environment, Su↗
DOE OSTI2023

An Architectural Survey of the Area 25 Nuclear Rocket Development Station, Nevada National Security Site, Nye County, Nevada, Volume 3 Of 3

The purpose of the current architectural survey is to record the Nuclear Rocket Development Station (NRDS) district, which is recommended eligible for listing to the NRHP under all four criteria as the testing center for the Rover/NERVA (Nuclear Engine for Rocket Vehicle Application) program from the initial boundary survey in 1956 to the end of nuclear rocket development on January 5, 1973. Resources in the NRDS district were evaluated to determine if they are eligible for listing to the National Register as district contributors. The current survey identified the Reactor Control Point subdistrict to provide a temporal, spatial, and functional framework for organizing the resources involved in the NRDS operations. However, the subdistrict was not evaluated as a potential historic district against the Secretary of Interior’s Significance Criteria.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

History and State of the Art in Advanced Thermal Protection Systems

This report documents the current state of the art of thermal protection systems (TPS) relevant to missile application materials and MTCR control language. The information is intended to provide data on current TPS for determining the current state of development and identifying potential research directions. Various vehicle configurations and types of TPS are described, including the evolution of materials and systems. Vehicle configurations such as high drag rocket and capsule systems and low-drag air-breathers are discussed. TPS are complex, transitioning from often very low temperatures to temperatures exceeding 3000°C and heat fluxes of up to 30,000 W/cm 2 . They can take the form of blankets, sheets, tiles and fabricated rigid structures, and can be made from high temperature capable alloys, refractory metals, ceramics, ceramic matrix composites, ultra-high temperature ceramics, carbon-carbon composites or ablative carbonaceous materials. Current state of the art in TPS is based on materials any systems developed for the initial space program. TPS was upgraded to the point of the Space Shuttle development and has stagnated since them.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Transient simulation of biomass combustion in a circulating fluidized bed riser

Interest in circulating fluidized bed (CFB) boilers as a power generation technology has sky-rocketed in recent years because of several advantages this technology offers over conventional boilers, such as increased gas-solid mixing, which results in higher combustion efficiency and the ability to use lower rank fuels. CFB combustors are operated at lower temperatures than conventional thermal power generation combustors, thus reducing NO x emissions, while SO 2 emissions can be conveniently controlled through the addition of Ca-based sulfur sorbents within the combustor. Herin this paper summarizes the modeling effort on a 50 kW th CFB combustor designed, built, and operated at CanmetENERGY in Ottawa, Canada. The numerical model employs the multiphase particle-in-cell (PIC) approach in the open-source Multiphase Flow with Interphase eXchanges (MFiX) Software Suite. The MFiX-PIC model parameters for the simulation are tuned against cold-flow experiments from CanmetENERGY using olivine sand as the inert bed material. It is shown that for the relatively coarse fluid meshes and large parcel sizes necessitated by the scale of the simulation, filter size dependent corrections to the drag law must be incorporated to ensure accuracy of the simulation results. The validated cold flow model is extended to simulate reacting flow with torrefied hardwood as the feedstock and to validate the combustion reaction scheme. The species concentrations at the riser outlet are compared against CanmetENERGY’s experiments and show satisfactory agreement. The simulations demonstrate the ability of MFiX-PIC to accurately capture both the physics and chemistry of a CFB combustor at bench scales, which can be further extended to pilot- and industrial-scale systems.

09 BIOMASS FUELS↗
DOE OSTI2023

Balancing Impedance and Controllability in Response Reconstruction with $\mathrm{TS-IMMAT}$

In a prior work the authors proposed a variant on the Impedance Matched Multi-Axis Test (IMMAT) in which a fixture is defined, called the Transmission Simulator (TS), and the desired environment is matched at a set of sensors on the TS. If the motion of the TS is matched then the response of the rest of the component will also match, provided that the attached component has the same dynamics as it did when the environment was measured. Hence, one would like the TS to be flexible so that it reproduces the boundary conditions that the component of interest experiences during flight, but the more flexible the TS, the more shakers might be needed to control its response. This work presents a derivation that gives expressions for these two potential error sources in TS-IMMAT. Then, various case studies are presented, both on simulated and real hardware, to understand the importance of each error term in practical testing. The theory explains the phenomena that were observed when using measurements from a component that flew on a sounding rocket. The environmental response was measured and then various fixtures were attached, each comprising more of the next assembly, or the hardware to which the component was attached in flight. MIMO testing was repeated with each fixture and the results were compared to seek to understand the role of the impedance match in this type of testing. Here the results show that the number of modes that are active in the transmission simulator is also very important, and so the best solution balances these two considerations. An improved method of simulating the MIMO test is then proposed, so simulations can be used to predict what fixture, or transmission simulator, will give the best results in a TS-IMMAT test.

42 ENGINEERING↗
DOE OSTI2020

Neutronics Analysis of Cold Critical KRUSTY Experiments using MCNP and Serpent

Kilowatt Reactor Using Stirling Technology (KRUSTY) is a prototype designed as a proof of concept for NASA’s Kilo power program, which was funded in order to create a small reactor for various space applications such as providing power for a colony on Mars or the moon and eventually as a possible option for powering rockets on deep space missions. KRUSTY was tested at the National Criticality Experiments Research Center (NCERC) located at the Nevada National Security Site (NNSS) from November 2017, through March 2018. The experimental campaign was conducted in four phases: com ponent critical experiments, cold critical experiments, warm critical runs, and high temperature demonstration. The component critical and cold critical experiments were used to determine the worth of the beryllium oxide (BeO) reflector rings and the boron carbide (B4C) control rod disks under different conditions. These conditions were altered by the addition and subtraction of other components in the assembly. The component critical phase was performed at atmospheric pressure and had four solid support rods spanning the center core; whereas the cold critical phase had the center core placed in a vacuum chamber and eight sodium-filled heat pipes spanning the center core region. This summary discusses the static neutronic analysis completed on the cold critical phase of the campaign using MCNP ® and Serpent. These two codes were used to assess any potential differences or biases in the simulation results. Understanding these potential biases is a key step toward the final goal of being able to fully analyze the transient experiments performed during phases 3 and 4 of the campaign.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2022

Neutronics Modeling of the pulsed plasma rocket reactor using rattlesnake

In the pulsed plasma rocket (PPR) reactor, neutron induced fission processes are utilized to implement a series of pulsed micro-explosions of very high power and eject plasma as a propellant. More specifically, projectiles (bullets) composed of moderated uranium are sent through the chamber of an unmoderated uranium barrel. By inducing rapid fission within the bullets, a plasma can be generated with appropriate delivery of neutrons. This study aims to assess the neutronics performance of the PPR reactor during normal operations using the MOOSE-based Rattlesnake code through the evaluation of the impact of the movement of the fuel bullet and the rotation of control drums on the criticality of the system. The Monte Carlo (MC) code Serpent 2 was employed to generate material-based cross sections for use in Rattlesnake and the reference neutronics solution. Cubit was used to generate the mesh for the Rattlesnake model. Parametric studies were conducted to evaluate the best approaches for cross section and mesh generation to ensure accurate results from Rattlesnake. As part of the verification process, the eigenvalue results of the system at various fuel bullet positions were obtained using Rattlesnake and compared with the reference solutions. The acceptable differences show that the Rattlesnake model with appropriate cross section and mesh generation procedure is a sufficiently accurate approximation of the continuous energy (CE) MC model for micro-sized reactors like the PPR reactor. Next, the impact of the rotation of the control drums on the system criticality was evaluated using the verified model. It was shown that the high-fidelity simulation using the deterministic code Rattlesnake can produce sufficiently accurate results for the evaluation of the reactor's neutronics performance in different phases of the normal operation with acceptable computational cost.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2025

Mitigation documentation for the removal of hazardous materials from the engine installation vehicle and manned control car area 25, Nevada national security site, NYE county, Nevada

The purpose of this letter report is to document the mitigation of adverse effects of a proposed undertaking that would remove hazardous materials from the Engine Installation Vehicle (EIV) in Area 25 of the Nevada National Security Site (NNNSS) in compliance with Section 106 of the National Historic Preservation Act (NHPA) and the terms of the 2024 Programmatic Agreement among the U.S. Department of Energy and the Nevada State Historic Preservation Officer and the Advisory Council on Historic Preservation Concerning the Protection of Historic Properties on the Nevada National Security Site, Nye County, Nevada, hereafter referred to as the NNSS PA. The EIV (State Historic Preservation Office [SHPO] Resource No. S3057) has been determined individually eligible for listing in the National Register of Historic Places (NRHP) under Criteria A and C and as a contributing element to the Nuclear Rocket Development Station (NRDS) Historic District, which is eligible for the NRHP under all four Significance Criteria (Reno et al. 2023; Reed 2024).

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI1968

Nuclear Physics Made Very, Very Easy

The fundamental approach to nuclear physics was prepared to introduce basic reactor principles to various groups of non-nuclear technical personnel associated with NERVA Test Operations. NERVA Test Operations functions as the field test group for the Nuclear Rocket Engine Program. Nuclear Engine for Rocket Vehicle Application (NERVA) program is the combined efforts of Aerojet-General Corporation as prime contractor, and Westinghouse Astronuclear Laboratory as the major subcontractor, for the assembly and testing of nuclear rocket engines. Development of the NERVA Program is under the direction of the Space Nuclear Propulsion Office, a joint agency of the U. S. Atomic Energy Commission and the National Aeronautics and Space Administration. This report is being reprinted for use in the U. S. Atomic Energy Commission and National Aeronautics and Space Administration educational and technology utilization programs.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

Technology Demonstration of a High-Pressure Swirl Oxy-Coal Combustor

This technical report presents the exploration of the design and prototyping of a High-Pressure Swirl Oxy-coal Combustor. Pressurized oxy-coal combustion systems have the potential to improve efficiency along with an increased carbon capture rate. Reduction of flue gas at higher pressure, smaller system size, and capital cost reductions render high-pressure oxy-coal systems particularly attractive as next-generation energy-producing systems. High-pressure oxy-coal combustion systems are a recent concept, and thus operability issues of combustor designs for such systems are not fully understood. Significant challenges exist to maintain oxy-coal combustion stability at elevated pressure and a high CO 2 diluent environment. Although a body of knowledge exists for high-pressure oxygen combustion in rocket engines (or similar applications), it is yet to be strategized how these fundamental concepts can be translated to low-temperature CO 2 diluent combustion regimes. The realization of the pressurized oxy-coal based systems requires combustor components to be designed and demonstrated for an operating pressure over 10 bar. However, pressurized oxy-coal combustor design information at this pressure range and scale relevant to validate those proposed systems is currently limited. Experimental data from MWth scale oxy-coal combustors are needed to identify the optimal trade-off between net efficiency and systems size. The proposed effort is aimed at demonstrating a 1 MWth down-fired swirl Oxy-Coal combustor and investigate the interrelation between combustor operating conditions (pressure; flame stability; flue gas recirculation ratio) and conversion efficiencies to minimize oxygen requirements. One of the key challenges is to configure burner design (i.e., swirl number and injector) and operating conditions for high-pressure oxy-coal combustion systems. These experiments differ from current systems partly due to the high theoretical flame temperature and related burner operability issues associated with oxy-combustion. An ASPEN PLUS® model study for 550 MWe TIPS and ENEL pressurized oxy-coal systems with CO 2 recirculation was performed to evaluate system design, subsystems sizing, and operating condition determination. The system analysis effort included TRL and technology gap determination of subsystems and critical components. This information was scaled to develop design requirements (design pressure and flue gas recirculation: RR Flue Gas = $\frac{m_{flue}}{m_{total}}$) for the 1 MWth combustor. The effects of a wide range of carbon dioxide recirculation ratios on the thermal efficiency of ENEL and TIPS cycles are studied. The pressure of 10 bar and 80 bar are used for ENEL and TIPS cycles, respectively. The thermal efficiency of ENEL is significantly higher than the efficiency of TIPS at a pressure of less than 10 bar. The insights from system analysis were then used to design a 1 MWth swirl oxy-coal combustor. Flame temperature analysis and material strength analysis was performed to determine the combustor thickness. The structural integrity of the combustor was validated by finite element analysis using Abacus® and Hypermesh®. Feasibility of igniters and secondary burners are investigated in successful high-pressure oxy-methane combustion. The secondary burners are designed in such a way that it can operate between 100 to 500 kW firing input. Three generations of the pintle injector were designed based on swirl numbers (S=0, 0.9, and 1.2). Key pintle injector parameters such as pintle size, pintle orifice size, spray pattern were investigated by cold flow tests. Information from these tests was used to modify injector design for smooth and successful operation. A 5 mm pintle orifice size was decided upon as the optimum size for oxy-coal operation for the combustor. Shadow sizing experiments were performed to identify the atomization rate of each injector. Different coal water slurry mixtures (30 – 50% coal by wt% in the mixture) at various total momentum ratios (TMR) were investigated for this purpose. These experiments provided decisive information to choose the best design of the injector. The injector with 1.2 swirl provided higher atomization in all cases than other designs. The mean equivalent droplet size of the jet was similar at different TMR and mixture ratios using this injector, thus making it suitable for use in most cases. Therefore, the 1.2 swirl-pintle injector was chosen for the shakedown test. The combustor and other sub-systems, including feed systems and control and data acquisition, have been manufactured, assembled, and integrated. The total system integration and installation began on July 1, 2020. The shake-down tests and initial operational capability demonstration are expected to be completed by September 30, 2020.

01 COAL, LIGNITE, AND PEAT↗